Pneumatic brake booster

A pneumatic brake booster, comprising:

• a generally cylindrical shaped piston having a first piston end and a second piston end and defining a chamber at the first piston end and a piston bore at the second piston end separated by an air flow aperture, the piston bore having a plunger aperture located at the second piston end;
• a plunger having a first plunger end and a second plunger end and being movable between first and second positions, the second plunger end being located within the plunger aperture;
• an air valve having a first valve end and a valve second end and being movable between first and second positions and defining a valve bore for receiving the first plunger end;
• and,
• a collapsing spring within the valve bore and being adapted to couple the plunger and the air valve, wherein the plunger and air valve are spaced apart a first relative distance in response to the pneumatic brake booster being in a regular apply mode and spaced apart a second relative distance in response to the pneumatic brake booster being in a panic apply mode, wherein the plunger includes a plunger trench near the first plunger end, and wherein the pneumatic brake booster further includes:
• a sleeve having a sleeve bore for receiving the second valve end and having a sleeve trench located around an interior surface of the sleeve;
• and,
• at least one ball bearing located within a bearing aperture in the air valve and being adapted to fit, alternatively, in the plunger trench and the sleeve trench.

A pneumatic brake booster, comprising:

• a generally cylindrical shaped piston having a first piston end and a second piston end and defining a chamber at the first piston end and a piston bore at the second piston end separated by an air flow aperture, the piston bore having a plunger aperture located at the second piston end;
• a plunger having a first plunger end and a second plunger end and being movable between first and second positions, the second plunger end being located within the plunger aperture;
• an air valve having a first valve end and a valve second end and being movable between first and second positions and defining a valve bore for receiving the first plunger end;
• and,
• a collapsing spring within the valve bore and being adapted to couple the plunger and the air valve, wherein the plunger and air valve are spaced apart a first relative distance in response to the pneumatic brake booster being in a regular apply mode and spaced apart a second relative distance in response to the pneumatic brake booster being in a panic apply mode;
• and,
• a sleeve having a sleeve bore for receiving the second valve end, a sleeve trench located around an interior surface of the sleeve, and a ridge on an exterior surface of the sleeve.

A pneumatic brake booster, comprising:

• a generally cylindrical shaped piston having a first piston end and a second piston end and defining a chamber at the first piston end and a piston bore at the second piston end separated by an air flow aperture, the piston bore having a plunger aperture located at the second piston end;
• a plunger having a first plunger end and a second plunger end and being movable between first and second positions, the second plunger end being located within the plunger aperture;
• an air valve having a first valve end and a valve second end and being movable between first and second positions and defining a valve bore for receiving the first plunger end;
• and,
• a collapsing spring within the valve bore and being adapted to couple the plunger and the air valve, wherein the plunger and air valve are spaced apart a first relative distance in response to the pneumatic brake booster being in a regular apply mode and spaced apart a second relative distance in response to the pneumatic brake booster being in a panic apply mode, wherein the air valve includes a slot located at the second valve end and the pneumatic brake booster further comprises a retaining ring having a generally C shape and being fitted into the slot on the air valve.

A pneumatic brake booster, comprising:

• a generally cylindrical shaped piston having a first piston end and a second piston end and defining a chamber at the first piston end and a piston bore at the second piston end separated by an air flow aperture, the piston bore having a plunger aperture located at the second piston end;
• a plunger having a first plunger end and a second plunger end and being movable between first and second positions, the second plunger end being located within the plunger aperture;
• an air valve having a first valve end and a valve second end and being movable between first and second positions and defining a valve bore for receiving the first plunger end;
• and,
• a collapsing spring within the valve bore and being adapted to couple the plunger and the air valve, wherein the plunger and air valve are spaced apart a first relative distance in response to the pneumatic brake booster being in a regular apply mode and spaced apart a second relative distance in response to the pneumatic brake booster being in a panic apply mode, wherein the air valve includes a bearing aperture located near the second end of the air valve and the pneumatic brake booster further comprises a plurality of ball bearings located within the bearing aperture and being adapted to fit, alternatively, in a plunger trench and a sleeve trench.

A pneumatic brake booster, comprising:

• a generally cylindrical shaped piston having a first piston end and a second piston end and defining a chamber at the first piston end and a piston bore at the second piston end separated by an air flow aperture, the piston bore having a plunger aperture located at the second piston end;
• a plunger having a first plunger end and a second plunger end and being movable between first and second positions, the second plunger end being located within the plunger aperture, the plunger including a plunger trench near the first end of the plunger;
• an air valve having a first valve end and a second valve end, the second valve end having a bearing aperture and defining a valve bore for receiving the first plunger end;
• a sleeve having a sleeve bore for receiving the second valve end and having a sleeve trench located around an interior surface of the sleeve;
• and,
• at least one ball bearing located within the bearing aperture and being adapted to fit, alternatively, in the plunger trench and the sleeve trench.

A pneumatic brake booster, comprising:

• a generally cylindrical shaped piston having a first piston end and a second piston end and defining a chamber at the first piston end and a piston bore at the second piston end separated by an air flow aperture, the piston bore having a plunger aperture located at the second piston end, the piston further including key apertures located between the air flow aperture and the plunger aperture;
• a bearing having a bearing bore adapted to receive the piston;
• a plunger having a first plunger end and a second plunger end and being movable between first and second positions, the second plunger end being located within the plunger aperture, the plunger including a plunger trench near the first plunger end;
• an air valve having a first valve end and a second valve end, the first valve end having a plurality of bearing apertures and defining a valve bore for receiving the first plunger end, the air valve further including first and second spaced apart radial valve elements located between the first and second valve ends and a slot located near the second valve end;
• a generally u-shaped key inserted through the key apertures, the key intersecting the air valve between the first and second spaced apart radial valve elements;
• a push rod having an interior cavity and being coupled to the second piston end;
• a rubber disk located within the interior cavity of the output rod and having an interior surface facing the plunger;
• a sleeve having a sleeve bore for receiving the first valve end, a sleeve trench located around an interior surface of the sleeve, and a ridge on an exterior surface of the sleeve;
• a retaining ring having a generally C shape and being fitted into the slot on the air valve;
• an abutment spring being located within the piston bore and between a first edge of the ridge on the sleeve and the plunger aperture;
• a sleeve spring being located within the piston bore and between a second edge of the ridge on the sleeve and an interior edge of the second radial valve element;
• a collapsing spring located within the valve bore and being adapted to couple the air valve and the plunger;
• and,
• a plurality of ball bearings located within the bearing apertures and being adapted to fit, alternatively, in the plunger trench and the sleeve trench.